• Client: A global retail customer via Rebl Industries AB  
• Industry: Retail, Logistics & Warehousing 
• Application: Vision Guided Robotics, Intelligent Palletizing  
• Photoneo Technology: MotionCam-3D 

 Summary 

A global retail customer in Sweden faced a significant ergonomic challenge with the manual handling of nearly two million uniquely sized parcels annually. To automate this heavy-duty task, automation partner Rebl Industries developed Rebl Palletizer, an AI-powered robotic workmate.  

The critical challenge was enabling the robot to handle a constant flow of random, unknown box sizes without stopping the line, where Photoneo played a key role with the industry-leading MotionCam-3D that works smoothly with Rebl’s Vision Guided Robotics (VGR) software, together serving as the “eyes” and “spatial intelligence” of the system.  

The Challenge: Automating the Mixed-Case Intelligent Palletizing in Motion 

The “wrap” station at the global retail customer is one of the most physically demanding jobs in the facility. Co-workers manually lift and stack parcels, weighing up to 20 kg each, from a sorting line into delivery cages. During a single shift, one person might handle over 1,000 packages. 

The primary obstacle to automation was variability. To minimize waste and shipping costs, the customer creates made-to-order boxes tailored to each product. This means the robotic cell would face a continuous stream of parcels with different dimensions, shapes, and weights.  

A traditional robot, programmed for standardized items, could not handle this task. 

The solution required a system that could: 

• Identify the precise 3D dimensions and orientation of each unique box.
• Operate at high speed (up to 450 pieces per hour) without stopping the conveyor. 
• Provide accurate data to an AI for intelligent stacking and path planning.
• Ensure reliable and safe gripping for objects up to 35 kg.

The Photoneo Solution: High-Fidelity Vision for Rebl’s AI-Powered Robotics 

While Rebl Industries provided the AI-driven robot in a flexible Robot-as-a-Service model, and Zebra Technologies supplied barcode scanners for sorting, the entire system hinged on one crucial capability: perception.  

The robot had to see, understand, and interact with the random flow of goods in real-time. This is where Photoneo’s technology became the core of the solution. 

Capturing Reality in Motion with MotionCam-3D

We provide our patented MotionCam-3D over the conveyor line. This scanner is unique in its ability to capture high-resolution, high-accuracy 3D point clouds of objects moving at high speeds.

As parcels travel down the line, the MotionCam-3D scans the scene for 3D data of each one, capturing its precise dimensions, volume, and position – all without ever needing the conveyor to stop.  

The complete workflow, powered by Photoneo’s vision, unfolds seamlessly: 

1. A parcel of any size enters the robotic cell on the conveyor. 
2. A Zebra FS40 barcode scanner reads its label, providing routing information.
3. As it passes under the MotionCam-3D, a detailed 3D scan is generated. 
4. This crucial 3D data is passed to the Rebl Workmate’s AI.
5. Rebl’s generative stacking AI uses the precise dimensions from our scan to determine the ideal placement on the pallet for maximum stability and density.
6. Rebl’s robot, guided by our vision software, executes a perfect pick-and-place operation.

Results: What Vision-Led Automation Delivers 

The implementation of Rebl Palletizer was a resounding success, achieving over 99% uptime and stability. This project, which went from plan to execution in just nine months, delivered transformative results for the global retail customer: 

• Solved a Major Ergonomic Problem: A physically taxing and repetitive job was successfully automated, improving the well-being of the Global Retail Customer’s co-workers. 

• Enabled High-Throughput Automation: By providing real-time 3D data without stopping the line, Photoneo’s technology allowed the system to meet its target of 450 pieces per hour. 

• Made “Impossible” Automation Possible: The challenge of handling random box sizes, a historic barrier for robotic palletizing, was overcome directly because of the high-quality perception our system provided. 

To get the full case study and see in fine detail what we achieved with Rebl Industries, how we did it and how can you follow suite with Rebl’s global retail customer, peek in and see the well-documented, quantified results. Go to download by clicking on the image below.